Will the castings on the Tesla Model Y be repairable if they get damaged? We have already asked a metallurgy expert about this, and Tesla has also published its manual. The answer is exactly as our reader predicted: in general, repairs are possible, but to a limited extent. There are also areas that can only be repaired after an expert opinion, who can of course conclude that the problem is so serious that the car is suitable for scrap.
Front casting in the Tesla Model Y – what can be repaired, what cannot be repaired
The green colour indicates areas that will withstand welding damage up to a maximum of 50 millimetres. Above 50 millimetres, it is necessary to contact Tesla experts. Places in yellow can repair damage up to a maximum of 30-50 millimetres in length, but require expert assessment. The orange and red areas require examination by Tesla experts, with damage in the red area potentially leading to the car being written off. Hardly surprising, there we have the stringers that protect the cabin (crumple zone) and the areas on which the entire body is supported (source).
That’s not all. The orange areas allow for welding damage of up to 30 millimetres and require an additional reinforcement plate, which has its own part number (1076938-E0-B). The plate is not welded, but glued in place. No welding is allowed in the red areas.
For bends/dents in the green, yellow and orange areas, cold straightening is permitted. After straightening, they must be within 1.5 millimetres of the original deviation. Heating is forbidden as it alters the structure and strength of the metal. Fragments of the damaged ribs can be replaced with replacements that are screwed into the casting.
In summary: repairs are mainly possible in areas that do not carry the greatest loads or are not safety-critical. When there is damage to the stringers (their ends are the rectangles at the bottom of the casting), the Tesla Model Y with the casting can end up in the scrap heap. Exactly the same, by the way, should happen to any other car, regardless of the type of drive.
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